RM2048A Rectifier Manual 1 0

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RM2048A Rectifier Manual

Revision 1.0

Rectronic Technologies

Email:[email protected]://www.rectronic.com

Copyright Rectronic Technologies Co., Ltd. 2013
http://www.rectronic.com/http://www.rectronic.com/http://www.rectronic.com/


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Rectifier Manual Page 2 of 13

TABLE OF CONTENTS

1 Principles of Operation .......................................................................................................... 3

1.1 Introduction .................................................................................................................... 3

1.2 Indicators ....................................................................................................................... 3

1.3 Power and Current Limit ................................................................................................ 4

1.4 Output Over-Voltage Shut Down .................................................................................... 4

1.5 Input Over/Under Voltage Shut Down ............................................................................ 4

1.6 Rectifier Soft Start and Inrush Current ........................................................................... 4

1.7 Over Temperature Turn Down/Shutdown ....................................................................... 4

1.8 Reverse Polarity Protection............................................................................................ 4

1.9 Active Load Share ......................................................................................................... 4

1.10 Fan Cooling ................................................................................................................... 4

1.11 Serial Alarm and Control Interface ................................................................................. 4

1.11.1 Voltage Control ...................................................................................................... 4

1.11.2 Rectifier Alarm states ............................................................................................. 5

1.11.3 Rectifier Shutdown ................................................................................................. 5

1.12 Hot Plug Capability ........................................................................................................ 5

1.13 Interface - Rear Connector............................................................................................. 6

2 Installation ............................................................................................................................. 8

2.1 General Warnings .......................................................................................................... 82.2 Rectifier Shelf ................................................................................................................ 8

2.3 AC Supply Surge Protection .......................................................................................... 8

2.4 Ventilation ...................................................................................................................... 8

2.5 Rectifier Addressing ....................................................................................................... 9

2.6 Commissioning the Rectifier .......................................................................................... 9

3 Specifications ...................................................................................................................... 10

3.1 AC Input: ...................................................................................................................... 10

3.2 DC Output: .................................................................................................................... 10

3.3 Environmental: ............................................................................................................. 11

3.4 Mechanical: ................................................................................................................. 113.5 Compliances ................................................................................................................ 11

4 Servicing ............................................................................................................................. 12

4.1 Warnings ..................................................................................................................... 12

4.2 Troubleshooting ........................................................................................................... 12

4.3 Fuses ........................................................................................................................... 12

5 Warranty .............................................................................................................................. 13


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1 Principles of Operation

1.1 Introduction

The RM2048A is a telecommunications grade rectifier with the following features:

Hot pluggable

Forced Air Cooled

Thermally Protected

Power Factor Corrected

Wide input AC Voltage

Constant Power Output Limit

Input/Output Voltage and Current Protected

Active Load Sharing

Serial alarm and control interface

Microprocessor controlled

1.2 IndicatorsThere are 3 LED indicators on the front panel indicate the operational state of the rectifier.

This green LED indicates that mains power is connected to the unit and that the primary stages ofthe rectifier are operating.

This yellow LED indicates a Non-Urgent alarm state within the rectifier. This could be caused bythe following:

Rectifier remote shutdown

Rectifier in AC input over/under voltage

Single fan failed

Rectifier no communication (The yellow LED is flashing)

This red LED indicates an Urgent alarm state within the rectifier. This could be caused by thefollowing:

Rectifier Failed

Rectifier shut down due to output over voltage or over temperature.

Double fans failed


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1.3 Power and Current Limit

The rectifier automatically limits its output as load demand reaches it maximum capacity.

1.4 Output Over-Voltage Shut Down

The rectifier will automatically shutdown if the output voltage exceeds the preset value. The Over VoltageShut Down point reduces by about 1V at full load to ensure the rectifier producing the Over Voltage ShutDown turns off first. The Over Voltage Shutdown voltage is preset in the factory but may be adjusted.

1.5 Input Over/Under Voltage Shut Down

If the input voltage is outside the specified range, the rectifier may shut down until the voltage returnswithin the specified range.

1.6 Rectifier Soft Start and Inrush Current

On start-up, the peak mains inrush current is limited to twice the maximum operating current. The outputvoltage and current will rise slowly from zero during start-up. This means that the AC input power slowlyincreases over a 2 second period, providing a gentle load characteristic for any standby generators.

1.7 Over Temperature Turn Down/Shutdown

When the rectifier reaches its maximum operating temperature (internal), the rectifier will progressivelyreduce the output current to attempt to reduce the heat within the unit. In extreme circumstances, therectifier internal temperature may continue to rise even with reduced output current. In this case therectifier will totally shutdown and will restart when the internal temperature returns within limits.

The maximum ambient operating temperature range at full power is: -25 to +65 C.

The rectifier will operate in ambient temperatures up to 65C but the rectifier will de-rate its output power tokeep internal temperatures within the allowable range.

1.8 Reverse Polarity Protection

The rectifier has an internal reverse polarity protection fuse and crowbar diode fitted. These parts are notuser serviceable, and the rectifier will require returning for servicing if incorrect polarity is applied to theoutput.

1.9 Active Load ShareThe rectifier will actively current share with other rectifiers in the same DC system. The hardware in eachrectifier looks at this current share bus and adjusts its output current to align with other rectifiers.

1.10 Fan Cooling

The rectifier constantly monitors its internal temperature, ambient temperature and output current, thenadjusts fan speed to ensure continued operation. This control of fan speed ensures that rectifier acousticnoise and dust accumulation are minimized.

If the fan fails and cannot be restarted then the fan failed. The rectifier will continue to operate as long asthe internal temperature stays within allowable limits.

1.11 Serial Alarm and Control Interface

The rectifier, when installed in a Rectronic rectifier shelf, is controlled via the serial interface by the systemmonitor. The system monitor can set up control parameters and receive alarm information via thisinterface.

If this interface is disconnected or fails for some reason the rectifier will operate with the parameters lastsent from the monitor. Current share will revert to the rectifier current share bus.

1.11.1 Voltage Control

The rectifier voltages are set by the system monitor via the serial communications bus. The rectifiervoltage can be set to any value between 42V and 60V. The monitor operates in a number of modes thatwill affect the rectifier voltage setting.

Float Voltage Mode (AVC Off)

The monitor sets the float voltage to its target level at start up, and then resends this same level atregular intervals thereafter. The voltage control is open loop.


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Float Voltage Mode (AVC On)

The monitor sets the system voltage to its target float voltage, then monitors the system voltageand adjusts rectifier voltages to maintain the system voltage at the desired float voltage.

Equalise Voltage Mode

The monitor sets the system voltage to an elevated level (e.g. 56V) for a fixed period, and then

resets the system voltage to the float voltage setting.

Fast Charge Mode

The monitor sets the system voltage to an elevated level after a battery discharge. This keeps therectifiers in current limit for a longer period, leading to a faster battery recharge. When the batteryis recharge the monitor resets the system voltage to the float voltage level.

1.11.2 Rectifier Alarm states

The rectifier will report the following states to the monitor via the serial communications:

AC Fail The AC supply is not present at the rectifier.

Rectifier Fail The rectifier is not functioning. This could be due to high output voltage, AC failureor a fault with the rectifier internally.

Over Temperature The internal temperature of the rectifier is too high and the rectifier has begun to limitits output to control this temperature.

Fan Fail The fan has ceased to work.

Current Limit The rectifier output has reached maximum and the output current is being limited.

Shutdown The rectifier has been shut down by the monitor. It will restart again in 5 minutesunless the shutdown instruction is repeated.

Soft Start The rectifier has just turned on and is slowly increasing its output.

1.11.3 Rectifier Shutdown

The rectifier can be remotely forced to shut down, via the serial communications, by the system monitorand/or remote supervisory software. The rectifier will shut down for 5 minutes then restart. If a furthershutdown signal is received by the rectifier before the 5 minutes is up, the timer will reset to 5 minutes.Hence, if a rectifier is to be kept shutdown a shutdown signal must be sent to it at regular intervals.

1.12 Hot Plug Capability

The rectifier is hot plug capable. This is achieved by having one pin on the rear circuit board thatconnects after the other pins. This pin must be connected to negative bus volts and the rectifier will notstart until this pin engages. If a rectifier will not start, ensure the rectifier is fully engaged in the connectorof the backplane in the rectifier shelf.


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1.13 Interface - Rear Connector

Definition for rectifier output pins as below:

Connector pin Layout (on the backplane)(view from rectifier plugging side):


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Pin descriptions

Pin # Function Description

Pin 1,3,5 OUT- Negative Output

Pin 2,4,6 OUT+ Positive Output

Pin 7,8,9 OUT- Negative Output

Pin 10 GND GND

Pin 11 12V Not more than 100mA

Pin 12 SHARE- Load Share-

Pin 13 5VGND 5V power supply to the RS485

Pin14 ADDR1 Module address signals.

Pin15SHARE+ Load Share+

Pin16 5V+ 5V power supply to the RS485

Pin17 RS485+ RS485+

Pin 18 RS485- RS485-

Pin 19,20,21 NC NC

Pin22 PE AC protective Earth

Pin23 L AC live (phase) conductor

Pin24 N AC neutral conductor


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2 Installation

2.1 General Warnings

This rectifier contains no user serviceable components. Do not disassemble the rectifier.

To isolate the rectifier from the mains power, simply unplug from the rack or switch off at the distribution

panel.

2.2 Rectifier Shelf

The RM2048A rectifier must only be used in conjunction with an appropriate Rectronic designed orRectronic approved system or rectifier shelf.

2.3 AC Supply Surge Protection

The AC supply that feeds the rectifiers should have surge protection installed to meet levels defined forterminal equipment. Rectronic recommend that IEC 62305-4 (Protection against lightning - Part 4:Electrical and electronic systems within structures) be used to give guidance on the design of surgesuppression systems.

2.4 Ventilation

The performance of the rectifier can be limited if the ventilation is restricted. The rectifier is cooled bydrawing air into the front of the unit with a single fan. This air passes through the rectifier cooling theelectronics and exiting the rectifier at the rear. To ensure this happens as efficiently as possible ensure thefollowing:

The air at the front of the rack is at ambient temperature and not being heated by other equipment.

Ensure the rectifier shelf has at least 75mm clear horizontal space behind it. This space must beclear of cables and any other components that may restrict air movement.(Note: if multiple rectifier shelves are installed then there should be at least 75mm clear horizontalspace per shelf.)

The free space in the rack should continue vertically to the exhaust point at the top of the rack,without impediment.

The hot exhaust air should not be allowed to re-circulate to the front of the rack as this will bedrawn into the rectifiers again, in effect raising the apparent ambient temperature.

The rectifier should be operated in a low dust environment. If this cannot be guaranteed, then the rackshould be fitted with air filters to prevent dust passing into the rectifier units. These filters need to bedesigned for adequate air volume and regularly maintained.

Note:If you are designing your own rectifier shelf, then particular care must be taken to ensure that anymetalwork, cable or printed circuit boards are placed to maximise the flow of cooling air. To assist in this adrawing of the rear area of the rectifier, show air flow areas, has been included in appendix 5.

DANGER

Do not operate the rectifier if the covers are damaged or removed in any way

- The rectifier contains voltages that may be lethal even after theinput supply has been removed

- The rectifier contains components at High Temperatures that mayburn if touched


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2.5 Rectifier Addressing

Each rectifier in the system has a unique address which identifies it to the monitor. This address is set bythe position in the rectifier shelf and the number of the shelf. It is read by the rectifier from the backplanePCB and will change if the rectifier is moved to a new location. This address structure is set up when thesystem is built by the system manufacturer.

2.6 Commissioning the Rectifier

1) Ensure the polarity of the load and battery cables to the backplane is correct.

2) Plug the rectifier into the rectifier shelf using the following steps:

Locate the metal tag (at the bottom/rear of the rectifier) into the chosen slot in the backplane.

Engage the plastic front panel into the slot at the front of the rectifier shelf.

Push the rectifier into the rectifier shelf until the connector is fully engaged.

Lock the rectifier in position using the plastic retainers in the front panel.

3) Once the rectifier is installed into the rectifier shelf, the AC power can be turned on. After the initialstart up period the rectifier will be set to the desired system parameters by the monitor module via

the serial communications.


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3 Specifications

Due to ongoing product development specifications are subject to change without prior notice

3.1 AC Input:

Nominal Voltage: 220V

Voltage Range: 90-300V (reduced power below 175V)

Maximum Input Current: 12.3A@175V

Frequency Range: 45-65 Hz

Power Factor: 0.99

Peak Efficiency: >93%

Protection:

Input Voltage: Auto shutdown, auto restart when correct voltage restored

Input Rush: 10ms for 20% output voltage drop

Start time: Start up delay 5 seconds.(varies with AC supply voltage )

Walk-in delay 3 seconds at full output. (varies with DC

output voltage)

Protection:

Current Limit: Adjustable to 50-100of maximum rated current

Over Temperature: Automatic current turndown, backup shutdown protection

Polarity Reversal: Output fuse with crowbar diode

Over voltage: Adjustable limit

Noise: (under nominal conditions)

Voice band: 2mV rms psophometric

Wide band: 3.4kHz-150kHz:


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150kHz-30MHz:


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4 Servicing

If the rectifier develops an operational fault, or is damaged in any way, an Authorised Service Centreshould service it immediately.

4.1 Warnings

This rectifier contains no user serviceable components. Do not disassemble the rectifier.

4.2 Troubleshooting

If the red LED is alight:

Unplug the rectifier and re-engage.

Check AC power to the rectifier.

Check for rectifier alarms in the monitor Urgent Alarm list.

If symptoms persist, contact a service agent.

If the yellow LED is alight:

Check the monitor Non-Urgent Alarm list.

4.3 Fuses

Although there are fuses inside the rectifier, these are rated such that their failure indicates a fault requiringqualified service. Do not attempt to repair these fuses.

DANGER

Do not operate the rectifier if the covers are damaged or removed in any way.

- The rectifier contains voltages that may be lethal even after the input supplyhas been removed

- The rectifier contains components at High Temperatures that may causeburns if touched


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5 Warranty

Rectronic Ltd warrants that this product is free from defects in material and workmanship and agrees toremedy any defect (or at its option replace the product) for a period of one year from the date of purchase.This warranty covers both parts and labour. Parts may be replaced under this warranty with new orremanufactured parts.

This warranty will not apply to any product that has been improperly installed (as described in theinstallation manual), misused, abused, used in ways the product was not designed, altered or repaired inany way which may affect the performance or reliability of operation, sustained damage by power surgesor electrical storms, or sustained shipping damage, or repaired by any unauthorised repair centre.

Please contact Rectronic Customer Service to obtain a Returned Materials Authorisation (RMA) prior toshipping any products for repair. All shipments must be shipped prepaid and include proof of the date ofyour original purchase. Please include your name, address, phone number, email address and a briefdescription of the problem.

Rectronic Ltd makes no other warranties, express or implied, including any warranty of fitness for aparticular purpose. In no event shall Rectronic be responsible for indirect or consequential damages or lost

profits even if Rectronic Ltd has been advised of the possibility of such damages. Rectronic Ltds soleobligation to you shall be the repair or replacement of a non-conforming product.

Documents

RM2048A Rectifier Manual 1 0